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Automatic Transmission/Torque Converter Clutch (TCC) Shudder, Water in Transmission (Repair Transmission and Replace Transmission Filler Tube, Level Indicator and Seal) Condition Some customers may comment on a shudder condition at approximately 64-80 km/h (40-50 mph) when the TCC engages. Cause This condition may be caused by water in the automatic transmission fluid (ATF). Water may enter the transmission by dripping from the cowl area onto the handle of the transmission fluid level indicator. Indications of water in the ATF may include: • Visible rust on the transmission fluid level indicator. • Visible water in the oil pan. • A milky white substance inside the pan area. • Spacer plate gaskets that appear to be glued to the spacer plate, valve body or case. • Rust on internal transmission iron/steel components. Correction First, repair the transmission and second, replace the transmission fill tube, seal and level indicator to prevent repeat water contamination of the ATF. Transmission Repair 1. Remove the transmission. Refer to the appropriate SI procedure. 2. Disassemble and inspect the transmission. Refer to Unit Repair Automatic Transmission – 4L60-E/4L65-E. Important: If water or coolant is found in the transmission, the following components MUST be replaced. • Replace all of the rubber type seals. • Replace all of the composition-faced clutch plate assemblies including the band. • Replace all of the nylon parts (Thrust Washers). • Replace the torque converter. • Thoroughly clean and rebuild the transmission, using new gaskets and oil filter. • Flush and flow check the transmission oil cooler using J 45096. Refer to Corporate Bulletin Number 02-07-30- 052C or newer – Automatic Transmission Oil Cooler Flush and Flow Test Essential Tool J 45096 TransFlow . Replace the Transmission Fluid Filler Tube, Seal and Fluid Level Indicator WITH the transmission REMOVED from vehicle. 1. Remove the transmission fluid filler tube from the transmission. 2. Replace the transmission fill tube seal, P/N 1259475. 3. Replace the transmission fill tube, P/N 15000220, following the appropriate SI Document for Transmission Installation. 4. Replace the transmission fluid level indicator, P/N 15069769 when appropriate during the transmission installation. Replace the Transmission Fluid Filler Tube, Seal and Fluid Level Indicator with the transmission in the vehicle. 1. Remove the air cleaner outlet duct. Refer to Air Cleaner Element Replacement (SI Document ID# 1364496). 2. Remove the transmission fluid level indicator from the filler tube.

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NOTICE: Whenever a transmission has been disassembled to install new parts, the transmission fluid cooler tubes must be cleaned and backflushed using a suitable torque converter/fluid cooler cleaner. A new Oil-To-Air (OTA) transmission fluid cooler must also be installed. When internal wear or damage has occurred in the transmission, metal particles, clutch plate material or band material may have been carried into the torque converter and fluid cooler. These contaminants are a major cause of recurring transmission concerns and must be removed from the system before the transmission is put back into service. NOTE: After the transmission is removed for a major overhaul, it is important to completely clean all transmission components, including torque converter, cooler inlet tube, main control valve body, clutches and all coasting booster valve shuttle balls after any transmission service that generates contamination. These contaminants are a major cause for recurring transmission concerns and must be removed from the system before the transmission is returned to service. The cleaning of foreign material from the direct clutch check ball is often omitted. This omission can lead to a repeat servicing of the transmission. A new Oil-To-Air (OTA) transmission fluid cooler must be installed under the following condition. For additional information, refer to Section 307-02. Evidence of broken transmission components or transmission fluid contamination found due to the following transmission or converter failure modes: Major metallic failure Multiple clutches or clutch plate failure Sufficient component wear which results in metallic contamination 1. Disconnect the battery ground cable. For additional information, refer to Section 414-01. 2. WARNING: Before servicing a vehicle equipped with a fire suppression system, depower the system by following the procedure in Section 419-03. Failure to follow the instructions may result in serious personal injury. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to Section 100-02. 3. NOTE: Only if transmission disassembly or replacement is required, drain the transmission fluid. For additional information, refer to Fluid Pan, Gasket and Filter in this section. Drain the transmission fluid. Loosen the transmission fluid pan bolts and allow the transmission fluid to drain. After transmission fluid has drained remove the bolts and the pan and drain the remaining transmission fluid that is in the pan. 4. Install the transmission fluid pan and the old transmission fluid pan gasket. 1. Position the transmission fluid pan gasket. 2. Position the transmission fluid pan. 5. NOTE: To maintain the initial driveshaft balance, mark the rear driveshaft yoke and the axle pinion flange so they can be installed in their original positions. Mark the rear driveshaft yoke and the axle pinion flange and remove the 4 bolts.

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Transmission Fluid Refill NOTICE: This procedure contains the air purge steps required to purge air from the cooling system. This procedure is NOT intended for use with the Transmission Fluid Level Check. NOTICE: The vehicle should not be driven if the fluid level is low as internal failure could result. NOTICE: The fluid fill plug is located near the exhaust system. The exhaust will be extremely hot during this procedure. NOTICE: The use of any other transmission fluid than specified, can result in the transmission failing to operate in a normal manner or transmission failure. NOTE: If the transmission starts to slip, shifts slowly or shows signs of fluid leaking, the fluid level should be checked. NOTE: Here is an overview of the Transmission Fluid Drain and Refill procedure. Adding 3.3L (3.5 qt) of clean automatic transmission fluid to the transmission is an initial fill enabling you to start the engine. The cold level range shown in the procedure allows the vehicle to be driven. The vehicle should be driven to allow the transmission fluid temperature to reach 85ºC-88ºC (185ºF-190ºF) in order to purge the air from the transmission cooling system. Fill the transmission fluid to the fill range on the fluid level indicator at the normal operating range 80ºC-85ºC (175ºF-185ºF). 1. NOTE: The transmission will need 3.3L (3.5 qt) of clean automatic transmission fluid added to the transmission as an initial fill if: the transmission has been overhauled. a new mechatronic assembly has been installed. the transmission fluid pan or fluid filter have been removed. Using the special tool, add 3.3L (3.5 qt) of clean automatic transmission fluid to the transmission through the fluid fill hole. For additional information, refer to Adding Additional Transmission Fluid in this procedure. 2. Check the transmission fluid level cold. 1. The vehicle is safe to drive if the transmission fluid is in the cold level range 32°C-43°C (90° F-11 0° F). Using the scan tool and the engine running, place the transmission selector lever in each gear position and hold approximately 5 seconds. Place the transmission selector lever in PARK, with the engine at idle (600-750 rpm).

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NOTICE: The use of any fluid other than what is recommended for this transmission will cause transmission damage. Draining 1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to Section 100-02. 2. Remove the transmission fluid drain plug and allow the transmission fluid to drain. Refill 3. Install the transmission fluid drain plug. Tighten to 47 Nm (35 lb-ft). 4. Remove the transmission fluid fill plug. 5. Fill the transaxle with approximately 3.7L (4 qt) of clean transmission fluid. 6. Install the transmission fluid fill plug. Tighten to 39 Nm (29 lb-ft). 7. With the transaxle in (P) PARK, the vehicle should be on a level surface, the engine at idle (680-780 rpm), foot pressed on the brake, move the selector lever through each gear and allow engagement of each gear. Place the selector lever back in the PARK position. 8. Wipe the transmission fluid level indicator cap and remove the fluid level indicator. 9. Wipe the transmission fluid level indicator with a clean cloth. 10. NOTE: In order to get an accurate transmission fluid level reading, the vehicle should be on a level surface, the engine at idle (680-780 rpm) for 5 minutes and the transmission fluid temperature should be at least 70°C-80° (158° C F-176° using the scan tool. F) If transmission fluid needs to be added, add transmission fluid in 0.25L (1/2 pint) increments through the transmission fluid fill plug located on the top of the transaxle near the transmission fluid level indicator. Do not overfill the transmission fluid. Install the transmission fluid level indicator back in the transmission fluid filler tube until it is fully seated, then remove the indicator. The transmission fluid level should be at the upper-most mark on the transmission fluid level indicator. Only fill to the upper-most mark on the transmission fluid indicator. Do not overfill. Damage to the transaxle will occur.

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Removal NOTE; NOTE: NOTE: Check and record all codes and actions of your transmission before transmission is removed. This will help if you still have problems after installation. Damage to your transmission may have been caused from some other external source. Deactivate air bag system before performing any service operation. See appropriate AIR BAG RESTRAINT SYSTEMS article in ACCESSORIES & EQUIPMENT. Do not apply any electrical power to any component on steering column without first deactivating air bag(s) system. AIR BAG MAY DEPLOY. When battery is disconnected, vehicle computer and memory systems may lose memory data. Drivability problems may exist until computer systems have completed a relearn cycle. See COMPUTER RELEARN PROCEDURES article in GENERAL INFORMATION before disconnecting battery. 1) Disconnect negative battery cable, remove dipstick, place transmission shift lever in the neutral position. Raise and support vehicle. 2) Remove all necessary skid plates if equipped. 3) Remove any engine to transmission struts (if equipped), and any exhausts components required for transmission removal. 4) Mark drive shaft and axel flange or yoke for reassembly reference, and remove drive shaft(s). 5) On all models, disconnect any shift linkage, wiring harnesses and control cables. NOTE: Use caution when pulling any wiring connectors. Do not pry on tabs or connectors with screwdriver. Slightly wiggle while pushing in or pulling out on tab(s). They should come out with a little patience. 6) On 4WD models, remove any shift linkage, cables, wiring harnesses, brackets and braces from transfer- case. 7) Remove transfer-case prior to removal of transmission. 8) On vehicles equipped with Power Take Off (PTO) unit, disconnect controls and remove. 9) On all models, remove necessary heat shields for access to electrical connectors. 10) Unplug all connectors from all turbine sensors, solenoid assembly, and speed sensors. 11) Remove starter and converter inspection cover. Rotate crankshaft clockwise and remove torque converter bolts (nuts) from drive plate (flex plate). 12) Remove transmission oil pan (or plug if equipped) to allow transmission to drain. 13) After transmission is drained, reinstall the pan (or plug) and place a jack under the transmission. 14) Slightly raise transmission with jack, and remove transmission mount and cross member. 15) Disconnect oil cooler lines, and remove filler tube. Cover all cooler line openings. 16) Secure the transmission to the transmission jack with safety straps or chains. 17) Remove all remaining transmission-to-engine bolts, and torque converter bolts. 18) Move transmission rearward aprox.1 to3 inches and slightly down. 19) Install a small C-clamp or other holding device, to hold torque converter in place while removing the transmission. 20) Do not remove the transmission all the way, only a few inches (1 to 3 ) at a time. Check to make sure everything is disconnected and clear.